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# Benha Faculty of Engineering

## Mechanical Engineering Department

Industrial Engineering M1382, 3rd year

Tutorials For
Industrial Engineering

Supervised By

## Eng. Yahya Abdelhameed Demonstrator, Mechanical Engineering Department

Industrial Engineering Tutorials

1) What is a new product?

## 4) Discuss the reasons and stages in the development of new product.

5) Briefly discuss each of these; Idea generation, Idea screening, concept testing.

## 8) Discuss the principles of commercialization.

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1) Define materials handling then write down the main types of materials handling
equipment.
2) What are the main objectives and goals of materials handling?
3) What are the different characteristics of materials which should be considered
when designing a material handling system?
4) Briefly discuss six principles from the materials handling principles.
5) Classify materials handling equipment. Giving examples of each type.
6) Compare between different types of (MH) equipment according to advantages &
7) What are the main sources of hazards in (MHS)?
8) Discuss safe lifting principles.
9) What are the main considerations for forklifts and how to be operated safely?
10) Give examples for the accessory items of (MHS).

11) A new belt conveyor which is required as a flow line of dry sand from the
warehousing to the sand casting workshop, two types of belt conveyors can be
used (flat or troughed) as the following figure:

- The following data were available: width of sand (b) = 80 cm, dynamic angle of
repose (Φ) = 30o, sand density = 1600 kg/m3, conveyor speed is 0.5 m/s. Find the
conveying capacity for two types of belt conveyor.
- If the length of flat belt conveyor is 10 m, and the mass of belt per meter is 12 kg/m,
and the moving mass of carrying and return idlers are 15 kg/m and 3 kg/m

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Industrial Engineering Tutorials

respectively, and the coefficient of friction between belt and idlers is 0.05. Find the
power required to drive this conveyor.

12) Boxes of size 220 mm * 180 mm * 100 mm are to be conveyed by belt conveyor of
sufficient bely length at rate of 2000 boxes/hr, what will be the size and speed of
the conveyor?

13) A forklift truck initially costs L.E. 200,000 and has an expected life of 5 years. Fuel
cost is L.E. 100.00 per 8 hours of operation, and maintenance cost is L.E. 15.0 an
hour. If the truck travels an average of 3,000 meter per day, determine the cost
per meter. Assume that the truck operates 360 days a year and that the operator
is paid L.E. 25.00 an hour.

14) A L.E. 100,000 tractor truck has an expected life of 8 years. The truck operates 280
days a year and travels an average of 5,000 meter per day. If the fuel costs about
L.E. 90.00 a day and maintenance costs are L.E. 7.5 an hour, determine the cost
per meter for operating this vehicle. Operator cost is L.E. 80.00/hour.

15) An Industrial robot is used in production facility load and unload workpieces from
a machine, these data table can be found:
Elemental Operation Times for a Robot
Activities Time (sec)
Machine operation time 25
Times associated with the robot
Move to the finished part conveyor 1.7
Release the unit 0.2
Move the arm to the input conveyor 2.6
Pick up a unit 0.3
Move to the machine 1.9

Find the cycle time using: one or two handed gripper, then find the total
production units in an 8-hour-per-day operation with 80% efficiency.

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Industrial Engineering Tutorials

16) Suppose an AGV system is chosen for delivering small parts from storage to four
shops in a plant, as shown in Figure. (Most guided vehicles can carry a load of 1000
to 4000 Kg) Determine the number of vehicles needed, given the information in
Table. (Assume that each vehicle can carry parts to and from only one shop at a
time) The AGVs under consideration can travel at a rate of 60 m/min. (Between 60
and 78 m/min is the normal speed for an AGV), and a congestion factor of 0.85.

## Table: AGV Distribution System Data

Shop No.
storage (m) (per hour) (min)
1 90 14 2
2 150 16 3
3 180 5 3
4 240 8 2

17) Parts needed for production in departments 1, 2, and 3 are moved from storage
by AGVs. Using the distance from the storage to each department as shown in
Figure, and given the number of trips that will be made per hour to each
accompanying table. Determine how many vehicles are needed. Assume an AGV
speed of 60 m/min and a congestion factor of 0.85.

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Industrial Engineering Tutorials

Department
(per hour) (min)
1 10 2
2 15 4
3 20 3

18) A single direction conveyor system has to be designed to meet a part flow rate of
60 parts per minute. Each container in the conveyor can hold 6 parts. The distance
conveyor speed and the allowable loading time if the spacing between the
containers is 1 m.

19) The oval of a top-driven carousel has a length of 15 m and a width of 1.5 m. The
speed of the carousel is 3 m/min, there are 60 carriers around the carousel and
each carrier contains only one bin, for a single and bidirectional carousel, compute
the average part retrieval time assuming a handling time of 30 s, Also, determine
the spacing between the carriers.

20) The proposed AGV system for a manufacturing unit must be capable of making 80
deliveries per hour. The type of AGV selected for this application has a velocity of
50 m/min. Based on the current facility layout, the average loaded travel distance
will be 150 m and the average empty travel distance will be 100 m. The total loading
determine the number of AGVs required.

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Industrial Engineering Tutorials

21) An overhead conveyor has hooks, and moves painted doors over a distance of 400
m in a single direction at 100 m/min between the paint station and the
intermediate storage area. The cycle time for painting a door is 2 min. Determine
the spacing between the hooks and the flow rate of parts in the conveyor system.

22) An automated guided vehicle system is used inside a telephone repair facility.
The vehicles move repaired telephones from the repair facility to the packing area.
Owing to the nature of the layout, the loaded travel distance is 300 m and the
empty travel distance is 500 m. The system must be able to move 750 phones per
hour. The load and unload time is about 1 min and the speed of the vehicle is 120
m/min. Determine the number of AGVs required. Knowing that each vehicle
capacity is 20 phones.

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Industrial Engineering Tutorials

1) Briefly discuss the basic types of inspection.

## 2) What are the different categories of receiving material inspection?

3) Briefly explain the inspection procedure for input material inspection for:
a) Self- Certification.
b) Inspection at supplier premises.
c) Inspection on receipt.

## 4) What are the requirements of inspection?

5) What are the points that should be indicated by Inspection and test results?

6) Give examples of statements that should not be exist in Inspection and Test Reports?

7) Write notes about instruments, gages, and tools used to perform official inspections.

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Industrial Engineering Tutorials

1) What are the objectives of facility layout?

## 3) Briefly Describe each of these layouts:

d) A process layout.
e) A product layout.
f) Cellular layout.

## 4) Compare between product and process layout according to:

b) Inventory
c) Material handling
d) Scheduling/line balancing

## 5) How can a cellular layout be useful, Give an example?

7) What is the function of: Activity Relationship Chart and From-To Chart?

8) Assign the six departments in next Figure to a 2 × 3 set of locations: Assign critical
departments first, because they are the most important.

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## 9) Assign nine automobile service departments to bays in a 3 × 3 grid so that the

closeness ratings in the following matrix are satisfied. The location of department
4 must be in the upper right-hand corner of the grid to satisfy a town ordinance.

10) Arrange the eight departments shown in the accompanying grid into a 2 × 4
format. Note: Department 1 must be in the location shown.

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11) Use the assignment method to determine the best way to assign machines to
locations, given the following cost information. Compute the total cost for your
assignment plan.

12) Assign trucks to delivery routes so that total costs are minimized, given the cost
data shown. What is the total cost?

13) The following table contains information on the cost to run three jobs on four
available machines. Determine an assignment plan that will minimize costs.

14) Develop an assignment plan that will minimize processing costs, given the
information shown:

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1) Define the method of time and motion study?

## 6) Briefly discuss the applications of time and motion study.

7) A job was timed for 60 cycles and had an average of 1.2 minutes per piece. The
performance rating was 95 percent, and workday allowances are 10 percent.
Determine each of the following:
a. Observed time.
b. Normal time.
c. Standard time.

8) A time study of an assembly operation yielded the following observed times for
one element of the job, for which the analyst gave a performance rating of 1.13
Using an allowance of 20 percent of job time, determine the appropriate standard
time for this operation.

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9) A time study was conducted on a job that contains four elements. The observed
times and performance ratings for six cycles are shown in the following table.

## a. Determine the average cycle time for each element.

b. Find the normal time for each element.
c. Assuming an allowance factor of 15 percent of job time, compute the standard
time for this job.

10) The data in the table below represent time study observations for a woodworking
operation, based on the observations, determine the standard time for the
operation, assuming an allowance of 15 percent of job time.

11) A new firm plans to produce 5000 units per day, the firm decided to purchase a
certain type of machine that takes 0.15 minute for one unit, knowing that the firm
will operate two shifts (8-hours) per day. Find the number of machines to be
purchased if the downtime is estimated to be 75 minutes per shift and the
performance efficiency is estimated to be 80%.

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Industrial Engineering Tutorials

1) Define the quality control.

## 9) Processing new accounts at a bank is intended to average 10 minutes each. Five

samples of four observations each have been taken. Use the sample data in
conjunction with given Table to construct upper and lower control limits for both
a mean chart and a range chart. Do the results suggest that the process is in
control?

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10) Checkout time at a supermarket is monitored using a mean and a range chart. Six
samples of n = 20 observations have been obtained and the sample means and
ranges computed.
a) Determine upper and lower limits for mean and range charts.
b) Is the process in control?

## 11) Computer upgrades have a nominal time of 80 minutes. Samples of five

observations each have been taken, and the results are as listed. determine upper
and lower control limits for mean and range charts, and decide if the process is in
control.

12) The time needed for checking in at a hotel is to be investigated. Historically, the
process has had a standard deviation equal to .146. The means of 39 samples of n
= 14 are:

## a) Construct an x-chart for this process with three-sigma limits.

b) Is the process in control?

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## X and R charts for quality control:

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1) For a certain product, the most recent revenue and cast figures show that: annual
fixed cost is \$ 90,000 and total variable cost is \$ 192,000, on sale 12,000 units, for
which total revenue is \$ 240,000, calculate:
a) The current unit variable cast and unit price.
b) The current loss or profit.
c) The reduced unit variable cost to break – even.
d) The reduced unit variable cost to have a profit \$ 10,000.

## 2) A machine shop can make an article on semi–automatic machine or an automatic

machine. Items of cost are:

## semi – automatic automatic

Items of cost
machine machine
Set up cost (LE) 4 6
Production rate (pcs/hr) 100 300
Labor cost ( LE/hr) 1.8 0.6
Overloads ( LE/hr ) 6 8

Compare the cost of each machine for the production of 2,000, 4,000, 6,000, 8,000
and 10,000 articles. Also, find the break – even point.

3) Sales forecasts indicate that a minimum of 5,000 units will be sold each year for
the next three years. Two design modifications are being considered for the
product. One modification will increase fixed costs by \$ 30,000 per year, but will
reduce variable costs by \$ 8 per unit. the other modification will increase fixed costs
by \$ 7,000 and reduce variable costs by \$ 6 per unit. Variable cost is currently \$ 30
per unit.
a) Which design modification should be adopted?
b) At what point, would you be indifferent to the two alternatives?

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4) A small company manufactures 20,000 units a year of rubber matt for the interiors
of cars. During the past year, a revenue of \$ 202,000 from sales was earned with
the given current cost:
Current operating cost
- Direct material \$ 51,000
- Direct labor \$ 12,000
- Maintenance \$ 11,000
- Property taxes and depreciation \$ 17,000
- Managerial and Sales expense \$ 35,000
Calculate:
a) What are the variable cost and selling price for the unit of car matt?
b) The breakeven production volume.
c) The present company loss or profit.

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